Dielectric insulation film

Abstract

Dielectric films are provided. Such films can be used in electric submersible pump stators, for example, as slot liners, phase barriers, or housing barriers. The film includes a polymeric matrix combined with an inorganic filler or reinforcing system.

What is claimed is: 
     
         1 . A dielectric film comprising:
 a polymeric matrix; and   an inorganic, thermally conductive filler.   
     
     
         2 . The dielectric film of  claim 1 , wherein the polymeric matrix is in a form of a sheet permanently bonded to a second sheet comprising a reinforcing fabric. 
     
     
         3 . The dielectric film of  claim 1 , wherein the filler is present in an amount exceeding 15% total volume. 
     
     
         4 . The dielectric film of  claim 1 , the filler comprising mineral and/or ceramic. 
     
     
         5 . The dielectric film of  claim 1 , the polymer matrix comprising one or more of PTFE, PFA, and polyimide PEEK. 
     
     
         6 . The film of  claim 1 , wherein the film comprises a plurality of thin layers. 
     
     
         7 . The film of  claim 6 , wherein the plurality of thin layers are not physically or chemically bonded together prior to insertion into a stator for an electric submersible pump. 
     
     
         8 . The film of  claim 7 , wherein the plurality of thin layers are locked in place in the stator during encapsulation of the stator with a rigid thermoset resin. 
     
     
         9 . The film of  claim 6 , wherein the film comprises at least one outer layer and at least one inner layer. 
     
     
         10 . The film of  claim 9 , wherein the at least one outer layer comprises water resistant PTFE or PFA composite. 
     
     
         11 . The film of  claim 9 , wherein the at least one outer layer comprises a low modulus, high elongation film. 
     
     
         12 . The film of  claim 9 , wherein the at least one inner layer comprises a high dielectric strength polyimide or polyimide composite. 
     
     
         13 . The film of  claim 9 , further comprising a surface treatment configured to improve compatibility with thermoset resin encapsulant of an electric submersible pump motor stator. 
     
     
         14 . The film of  claim 1 , further comprising a surface treatment configured to improve compatibility with thermoset resin encapsulant of an electric submersible pump motor stator. 
     
     
         15 . A method of making a dielectric film, the method comprising:
 sandwiching together one or more inner layers of a first material with one or more outer layers of a second material.   
     
     
         16 . The method of  claim 15 , wherein the inner and outer layers are not physically or chemically bonded together prior to insertion into a stator, further comprising inserting the film into a stator, and encapsulating the stator with a rigid thermoset resin, thereby mechanically locking the inner and outer layers in place. 
     
     
         17 . A method of making a dielectric film, the method comprising incorporating an inorganic filler into a polymeric matrix. 
     
     
         18 . The method of  claim 17 , wherein the filler is incorporated into the polymeric matrix in an amount exceeding 15% total volume. 
     
     
         19 . The dielectric film of  claim 1 , wherein the polymeric matrix is in a form of a sheet permanently bonded to a second sheet comprising glass. 
     
     
         20 . The method of  claim 15 , further comprising applying a surface treatment to the film, the surface treatment configured to improve compatibility with a thermoset resin encapsulant of an electric submersible pump motor stator.